Hip and ridge roofing material

ABSTRACT

Shingle blanks including a first fold region, a second fold region, a third region, a lower edge and an upper edge are provided. The shingle blank has a length. The first and second fold regions extend substantially across the length of the shingle blank. The second fold region is positioned between the first and third fold regions. A first perforation line is positioned between the second and third fold regions. A second perforation line is positioned between the first and second fold regions. A reinforcement material is positioned over the first perforation line and configured to reinforce the first perforation line. The reinforcement material includes apertures configured to allow an asphalt coating to bleed through the reinforcement material. The first and second perforation lines facilitate folding of the first and second fold regions on top of the third region to form a three layered stack.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of co-pending U.S.patent application Ser. No. 12/392,392, entitled HIP AND RIDGE ROOFINGMATERIAL, filed Feb. 25, 2009, the disclosure of which is incorporatedherein by reference in its entirety.

BACKGROUND

Asphalt-based roofing materials, such as roofing shingles, roll roofingand commercial roofing, are installed on the roofs of buildings toprovide protection from the elements. The roofing material may beconstructed of a substrate such as a glass fiber mat or an organic felt,an asphalt coating on the substrate, and a surface layer of granulesembedded in the asphalt coating.

Roofing materials are applied to roofs having various surfaces formed byroofing planes. The various surfaces and roofing planes formintersections, such as for example, hips and ridges. A ridge is theuppermost horizontal intersection of two sloping roof planes. Hips areformed by the intersection of two sloping roof planes running from aridge to the eaves. It would be desirable to improve the methods used tomanufacture hip and ridge roofing material to be more efficient.

SUMMARY

In accordance with embodiments of this invention there are providedshingle blanks. The shingle blanks include a substrate coated with anasphalt coating and including a first fold region, a second fold region,a third region, a lower edge and an upper edge. The shingle blank has alength and the first fold region extends substantially across the lengthof the shingle blank. The second fold region extends substantiallyacross the length of the shingle blank and is positioned between thefirst fold region and the third region. A first perforation line ispositioned between the second fold region and the third region. A secondperforation line is positioned between the first fold region and thesecond fold region. A reinforcement material is positioned over thefirst perforation line and is configured to reinforce the firstperforation line. The reinforcement material includes a plurality ofapertures configured to allow the asphalt coating to bleed through thereinforcement material. The first and second perforation lines aresufficient to facilitate folding of the first fold region and the secondfold region on top of the third region to form a three layered stackconfigured to be applied across a ridge or hip.

In accordance with other embodiments, there are also provided shingleblank having a substrate coated with an asphalt coating and including afirst fold region, a second fold region, a third region, a lower edgeand an upper edge. The shingle blank has a length and the first foldregion extends substantially across the length of the shingle blank. Thesecond fold region extends substantially across the length of theshingle blank and is positioned between the first fold region and thethird region. A first perforation line is positioned between the secondfold region and the third region. A second perforation line ispositioned between the first fold region and the second fold region. Arelease tape is positioned over the second perforation line andconfigured to span a portion of the first fold region and the secondfold region. The release tape is configured to reinforce the secondperforation line. The first and second perforation lines are sufficientto facilitate folding of the first fold region and the second foldregion on top of the third region to form a three layered stackconfigured to be applied across a ridge or hip.

In accordance with other embodiments, there are also provided methods ofmanufacturing an asphalt-based shingle blank including the steps ofcoating a substrate with an asphalt coating to form an asphalt coatedsheet, the asphalt coated sheet including a first fold region, a secondfold region, a third region, a lower edge and an upper edge, the shingleblank having a length, the first fold region extending substantiallyacross the length of the shingle blank, the second fold region extendingsubstantially across the length of the shingle blank and positionedbetween the first fold region and the third region, applying areinforcement material to a portion of an upper surface of the asphaltcoated sheet and over the first perforation line, the reinforcementmaterial including a plurality of apertures configured to allow theasphalt coating to bleed through the reinforcement material, applying asurface layer of granules to the upper surface of the asphalt coatedsheet, forming a first perforation line between the second fold regionand the third region and forming a second perforation line between thefirst fold region and the second fold region.

In accordance with other embodiments, there are also provided methods ofinstalling an asphalt-based roofing material including the steps ofproviding an asphalt-based shingle blank having a substrate coated withan asphalt coating and including a first fold region, a second foldregion, a third region, a lower edge and an upper edge, the shingleblank having a length, the first fold region extending substantiallyacross the length of the shingle blank, the second fold region extendingsubstantially across the length of the shingle blank and positionedbetween the first fold region and the third region, a first perforationline positioned between the second fold region and the third region, asecond perforation line positioned between the first fold region and thesecond fold region, wherein at least one additional perforation lineextends across the shingle blank in a direction substantiallyperpendicular to the lower edge of the shingle blank, a reinforcementmaterial positioned over the first perforation line and configured toreinforce the first perforation line, the reinforcement materialincluding a plurality of apertures configured to allow the asphaltcoating to bleed through the reinforcement material, separating theshingle blank along the at least one additional perforation line to formseparated shingle blanks, folding the separated shingle blanks along thefirst and second perforation lines to form a three layered stack andinstalling the hip and ridge shingles across a hip or ridge.

Various advantages of this invention will become apparent to thoseskilled in the art from the following detailed description of theinvention, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a building structure incorporating thehip and ridge roofing material in accordance with embodiments of thisinvention.

FIG. 2 is a perspective view of the installation of the ridge roofingmaterial of FIG. 1.

FIG. 3 is a perspective view of an upper surface of a shingle blank usedfor making the hip and ridge roofing material of FIG. 2.

FIG. 4 is a perspective view of a bottom surface of a shingle blank usedfor making the hip and ridge roofing material of FIG. 2.

FIG. 5 is an enlarged cross-sectional view, taken along the line 5-5 ofFIG. 3, of a portion of the hip and ridge roofing material of FIG. 3.

FIG. 6 is a perspective view of the shingle blank of FIG. 3 illustratingthe formation of the individual hip and ridge roofing material of FIG.2.

FIG. 7 is a side view in elevation of the individual hip and ridgeroofing material of FIG. 6 prior to forming the hip and ridge roofingmaterial of FIG. 2.

FIG. 8 is a side view in elevation of an individual hip and ridgeroofing material of FIG. 6 illustrating the folds forming the hip andridge roofing material of FIG. 2.

FIG. 9 is a side view in elevation of an individual hip and ridgematerial of FIG. 2.

FIG. 10 is a schematic view in elevation of apparatus for manufacturingthe hip and ridge roofing material of FIG. 2.

FIG. 11 is a plan view of a reinforcement material used in the hip andridge roofing material of FIG. 2.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described with occasional reference tothe specific embodiments of the invention. This invention may, however,be embodied in different forms and should not be construed as limited tothe embodiments set forth herein. Rather, these embodiments are providedso that this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs. The terminology used in thedescription of the invention herein is for describing particularembodiments only and is not intended to be limiting of the invention. Asused in the description of the invention and the appended claims, thesingular forms “a,” “an,” and “the” are intended to include the pluralforms as well, unless the context clearly indicates otherwise.

Unless otherwise indicated, all numbers expressing quantities ofdimensions such as length, width, height, and so forth as used in thespecification and claims are to be understood as being modified in allinstances by the term “about.” Accordingly, unless otherwise indicated,the numerical properties set forth in the specification and claims areapproximations that may vary depending on the desired properties soughtto be obtained in embodiments of the present invention. Notwithstandingthat the numerical ranges and parameters setting forth the broad scopeof the invention are approximations, the numerical values set forth inthe specific examples are reported as precisely as possible. Anynumerical values, however, inherently contain certain errors necessarilyresulting from error found in their respective measurements.

In accordance with embodiments of the present invention, a hip and ridgeshingle, and methods to manufacture the hip and ridge shingle, areprovided. It will be understood the term “ridge” refers to theintersection of the uppermost sloping roof planes. The term “roof plane”is defined to mean a plane defined by a flat portion of the roof formedby an area of roof deck. The term “hip” is defined to mean theintersection of sloping roof planes located below the ridge. It will beunderstood the term “slope” is defined to mean the degree of incline ofa roof plane. The term “granule” is defined to mean particles that areapplied to a shingle that is installed on a roof.

The description and figures disclose a hip and ridge roofing materialfor a roofing system and methods of manufacturing the hip and ridgeroofing material. Referring now to FIG. 1, a building structure 10 isshown having a shingle-based roofing system 12. While the buildingstructure 10 illustrated in FIG. 1 is a residential home, it should beunderstood that the building structure 10 can be any type of structure,such as a garage, church, arena, industrial or commercial building,having a shingle-based roofing system 12.

The building structure 10 has a plurality of roof planes 14 a-14 d. Eachof the roof planes 14 a-14 d can have a slope. While the roof planes 14a-14 d shown in FIG. 1 have their respective illustrated slopes, itshould be understood that the roof planes 14 a-14 d can have anysuitable slope. The intersection of the roof planes 14 b and 14 c form ahip 16. Similarly, the intersection of the roof planes 14 b and 14 dform a ridge 18. The building structure 10 is covered by the roofingsystem 12 having a plurality of shingles 20.

Referring now to FIG. 2, the shingles 20 are installed on the variousroof decks in generally horizontal courses 22 a-22 g in which theshingles 20 overlap the shingles 20 of a preceding course. The shingles20 shown in FIGS. 1 and 2 can be any suitable shingle.

Hip and ridge roofing materials are installed to protect hips and ridgesfrom the elements. As shown in FIG. 2, hip and ridge roofing materials24 are installed in an overlapping manner on the ridge 18 and over theshingles 20. In a similar fashion, hip roofing materials (not shown) areinstalled on a hip and over the shingles. The method of installing thehip and ridge roofing materials 24 will be discussed in more detailbelow.

Referring now to FIGS. 3 and 4, hip and ridge roofing materials 24 aremade from a shingle blank 26. The shingle blank 26 has an upper surface27 a, a lower surface 27 b, an upper edge 29 a, a lower edge 29 b, agenerally horizontal first perforation line 34 and a generallyhorizontal second perforation line 40.

As shown in FIG. 3, a reinforcement material 36 is positioned on theupper surface 27 a of the shingle blank 26 and over the firstperforation line 34. The reinforcement material 36 is configured forseveral purposes. First, the reinforcement material 36 is configured toprevent breakage of the shingle blank 26 as the shingle blank 26 isfolded about the first perforation line 34. Second, as will be explainedin more detail below, the reinforcement material 36 is configured toallow asphaltic material to bleed through the reinforcement material 36,thereby providing a surface for subsequently applied one or more layersof granules to adhere to. In the illustrated embodiment, thereinforcement material 36 is a tape made from a polymeric film material,such as for example polyester. In other embodiments, the reinforcementmaterial 36 can be made from other desired materials, such as thenon-limiting examples of a low permeability mat or scrim made fromfibrous materials or netting. In the illustrated embodiment, thereinforcement material 36 extends substantially across the length L ofthe shingle blank 26. The term “substantially” as used herein, isdefined to mean any desired distance in a range of from betweenapproximately one-half of the length L to the full length L.

Referring now to FIG. 11, the reinforcement material 36 is illustrated.The reinforcement material 36 has a width WRM and a thickness. In theillustrated embodiment, the width WRM of the reinforcement material 36is in a range of from about 1.0 inches to about 2.0 inches and thethickness is in a range of from about 50 gauge to about 96 gauge. Inother embodiments, the width WRM of the reinforcement material 36 can beless than about 1.0 inches or more than about 2.0 inches and thethickness can be less than about 50 gauge or more than about 96 gauge.

As shown in FIG. 11, the reinforcement material 36 includes a pluralityof apertures 37. The apertures 37 are configured to allow asphalticmaterial to bleed through the reinforcement material 36. In theillustrated embodiment, the apertures 37 are arranged in a pattern ofcolumns and rows are present in concentrations of approximately 330 persquare inch. Alternatively, the apertures 37 can be arranged randomly orin other patterns and can have concentrations of less than 330 persquare inch or more than 330 per square inch. In the illustratedembodiment, the apertures 37 have a circular shape with diameter in arange of from about 300 microns to about 500 microns. Alternatively, theapertures 37 can have a diameter less than about 300 microns or morethan about 500 microns. In still other embodiments, the apertures 37 canhave other desired shapes, including the non-limiting examples ofsquare, and polygonal shapes as well as slits.

Referring again to FIG. 3, the shingle blank 26 may have any desireddimensions. For example, a typical residential roofing shingle blank 26has a length L of approximately 36 inches (91.5 cm) and a height H ofapproximately 12 inches (30.5 cm) high. However, it will be understoodthan other desired dimensions may be used.

As shown in FIG. 3, the shingle blank 26 includes a first fold region 25a, a second fold region 25 b and a third region 30. The first foldregion 25 a is the area between the second perforation line 40 and theupper edge 29 a. The first fold region 25 a is configured to provide anailing surface for the installation of the ridge or hip roofingmaterial 24 and further configured to provide an optional sealant area.The optional sealant bonding area will be discussed in more detailbelow. The second fold region 25 b is the area between the secondperforation line 40 and the first perforation line 34. The first foldregion 25 a has a height HFF, the second fold region 25 b has a heightHSF and the third region 30 has a height HT. In the illustratedembodiment, the height HFF is approximately 2.0 inches, the height HSFis approximately 2.0 inches and the height HT is approximately 8.0inches. In other embodiments the heights HFF, HSF and HT can be otherdesired dimensions, and it will be understood that the heights HFF, HSF,and HT are largely a matter of design choice.

Referring again to FIG. 3, the first fold region 25 a, second foldregion 25 b and third region 30 extend substantially across the length Lof the shingle blank 26.

As further shown in FIG. 3, the shingle blank 26 includes a third andfourth perforation line, 60 and 62. As will be discussed in more detailbelow, the third and fourth perforation lines, 60 and 62, are configuredto allow separation of the shingle blank 26 into three pieces, therebyforming ridge or hip roofing materials 24.

Referring again to FIG. 3, optionally the shingle blank 26 can include asealant line 66 b. The sealant line 66 b is configured to provide anadhesive seal for subsequent overlapping ridge roofing materials 24. Thesealant line 66 b can be any suitable adhesive and can be applied in anyform or configuration in any location. In one embodiment, the sealantline 66 b can be a continuous strip, not shown or continuous strips, notshown, having a constant width. Alternatively, the sealant line 66 b canbe a discontinuous strip or strips having varying widths. One example ofa sealant line is the sealant line of the type disclosed in U.S. Pat.No. 4,738,884 to Algrim et al., the disclosure of which is incorporatedherein in its entirety.

Referring now to FIG. 4, the lower surface 27 b of the shingle blank 26includes a release tape 39 and an optional sealant line 66 a. Therelease tape 39 is positioned on the lower surface 27 b of the shingleblank 26 in a location suitable to cover the optional sealant line 66 band also to cover the second perforation line 40. The release tape 39 isconfigured for several purposes. First, the release tape 39 isconfigured to cover the optional sealant line 66 b as shingle blanks 26are stacked for storage or shipping. Second, the release tape 39 isconfigured to prevent breakage of the shingle blank 26 as the shingleblank 26 is folded about the second perforation line 40. In theillustrated embodiment, the release tape 39 is made of a polymeric filmmaterial having a thickness in a range of about 30 gauge to about 96gauge. In other embodiments, the release tape 39 can be made of otherdesired materials or combinations of materials and can have thicknessesless than about 30 gauge or more than about 96 gauge.

Referring again to FIG. 4, the optional sealant line 66 a is configuredto provide an adhesive seal for subsequent overlapping ridge roofingmaterials 24. In the illustrated embodiment, the sealant line 66 a isthe same as the optional sealant line 66 b illustrated in FIG. 3 anddiscussed above. Alternatively, the sealant line 66 a can be differentfrom the sealant line 66 b. In some embodiments, when the shingle blanks26 are stacked for storage and shipping, the shingle blanks 26 areflipped such that the release tape 39 of one shingle blankssubstantially aligns with the sealant line 66 a of a subsequentlystacked shingle blank. This alignment allows for easy separation of thestacked shingle blanks 26 at an installation site.

Referring again to the embodiment illustrated in FIG. 4, the releasetape has a width WRT in a range of from about 3.00 inches to about 4.00inches. However, in other embodiments, the width WRT of the release tapecan be less than about 3.00 inches or more than about 4.00 inches. Instill other embodiments, the release tape 39 can have any desiredcoatings.

Referring now to FIG. 5, one embodiment of the composition of theshingle blank 26 is illustrated. The shingle blank 26 includes asubstrate 44 that is coated with an asphalt coating 46. The substrate 44can be any suitable substrate for use in reinforcing asphalt-basedroofing materials, including, but not limited to a nonwoven web, scrimor felt of fibrous materials such as glass fibers, mineral fibers,cellulose fibers, rag fibers, mixtures of mineral and synthetic fibers,or the like. Combinations of materials can also be used in the substrate44.

The asphalt coating 46 includes an upper section 48 that is positionedabove the substrate 44 when the roofing material is installed on a roof,and a lower section 50 that is positioned below the substrate 44. Theupper section 48 includes an upper surface 52. The term “asphaltcoating” means any type of bituminous material suitable for use on aroofing material, including, but not limited to asphalts, tars, pitches,or mixtures thereof. The asphalt can be either manufactured asphaltproduced by refining petroleum or naturally occurring asphalt. Theasphalt coating 46 can include various additives and/or modifiers, suchas inorganic fillers or mineral stabilizers, organic materials such aspolymers, recycled streams, or ground tire rubber.

The reinforcement material 36 is positioned on the upper surface 52 ofthe upper section 48 such that portions of the asphalt coating 46 bleedthrough the apertures (not shown) within the reinforcement material 36.The portion of the asphalt coating 46 that has bled through thereinforcement material 36 forms a reinforced portion 51 of the uppersection 48. The reinforced portion 51 of the upper section 48 has athickness TRP. In the illustrated embodiment, the thickness of thereinforced portion 51 is in a range of from about 0.05 inches to about0.30 inches. In other embodiments, the thickness TRP of the reinforcedportion 51 can be less than about 0.05 inches or more than about 0.30inches.

A layer of granules 42 is pressed into the upper surface 52 and thereinforced portion 51 of the upper section 48. The granules 42 can beany desired granules or combination of granules. Some examples ofgranules include prime, headlap granules or waste granules. Optionally,the lower section 50 can be coated with a suitable backdust material 54.

Referring now to FIG. 6, the shingle blank 26 includes the thirdperforation line 60 and the fourth perforation line 62. The third andfourth perforation lines, 60 and 62, include perforations 64. The thirdand fourth perforation lines, 60 and 62, are spaced apart substantiallyperpendicular to the lower edge 29 b of the shingle blank 26 and spanthe height H of the shingle blank 26. The third and fourth perforationlines, 60 and 62, are positioned such that subsequent separation of theshingle blank 26 along the third and fourth perforation lines, 60 and62, forms hip and ridge shingle blanks 69. In the illustratedembodiment, the formed hip and ridge shingle blanks 69 has a length ofapproximately 12.0 inches. In other embodiments, the third and fourthperforation lines, 60 and 62, can be positioned relative to each other,to result in formed hip and ridge shingle blanks 69 having lengths ofmore or less than approximately 12.0 inches. In still other embodiments,the shingle blank 26 can have more than two perforation lines (notshown), spaced apart substantially perpendicular to the lower edge 29 bof the shingle blank 26 and spanning the height H of the shingle blank26. The additional perforation lines can be configured to separate theshingle blank 26 thereby forming hip and ridge shingle blanks of anydesired sizes.

In the illustrated embodiment, the perforations 64 extend through theupper section 48 of the asphalt coating 46, the substrate 44 and thelower section 50 of the asphalt coating 46. In other embodiments, theperforations 64 can extend through any suitable layers of the shingleblank 26. The perforations 64 can be arranged in any suitable pattern toform the third and fourth perforation lines, 60 and 62.

In one example of a perforation pattern, the perforations 64 can beabout 0.25 inches long and spaced apart from edge to edge by about 0.25inches. In another embodiment of a perforation pattern, the perforations64 can be about 0.50 inches long and spaced apart from edge to edgeabout 0.50 inches. Alternatively, the perforations 64 can be anysuitable length and can be spaced apart edge to edge by any suitablelength. The perforations 64 are configured such that an installer isable to separate the shingle blanks 26 into the hip and ridge shingleblanks 69 at the installation site. In the illustrated embodiment, thethird and fourth perforation lines, 60 and 62, extend the full height Hof the shingle blank 26. Alternatively, the third and fourth perforationlines, 60 and 62, can extend any length sufficient to enable aninstaller to separate the shingle blanks 26 into the ridge shingleblanks 69 at an installation site.

Referring again to FIG. 6, optionally a plurality of headlap courtesycuts 68 a are positioned in the first fold region 25 a and a pluralityof prime courtesy cuts 68 b are positioned in the third region 30 of theshingle blank 26. In the illustrated embodiment, the headlap courtesycuts 68 a are configured to substantially align with a correspondingprime courtesy cut 68 b, and the aligned headlap and prime courtesycuts, 68 a and 68 b, are further aligned along the perforation lines, 60and 62. As shown in the illustrated embodiment, the headlap courtesycuts 68 a and the prime courtesy cuts 68 b extend substantially throughthe thickness of the shingle blank 26. In other embodiments, thecourtesy cuts, 68 a and 68 b, can extend through any suitable layers ofthe shingle blank 26. The headlap and prime courtesy cuts, 68 a and 68b, have a length. In the illustrated embodiment, the length of theheadlap and prime courtesy cuts, 68 a and 68 b, is in a range of fromabout 1.0 inches to about 5.0 inches. In other embodiments, the lengthof the headlap and prime courtesy cuts, 68 a and 68 b, can be less thanabout 1.0 inches or more than about 5.0 inches. While the illustratedembodiment shows the headlap courtesy cuts 68 a and the prime courtesycuts 68 b as being the same length, it should be understood that headlapcourtesy cuts 68 a and the prime courtesy cuts 68 b can be differentlengths. The courtesy cuts, 68 a and 68 b, are configured to assist theinstaller in separating the shingle blanks 26. As will be explainedbelow in more detail, the courtesy cuts, 68 a and 68 b, are provided inthe shingle blank 26 during the manufacture of the shingle blank 26.

Referring again to FIG. 6, the shingle blanks 26 arrive at theinstallation site having third and fourth perforation lines 60 and 62.During installation, the roofing installer separates the shingle blank26 along the third and fourth perforation lines, 60 and 62 to form thehip and ridge shingle blanks 69. The perforations 64 allow for hip andridge shingle blanks 69 to be formed from the shingle blanks 26 as theperforations 64 allow the substrate 44 and asphalt regions, 48 and 50,to be readily separated. The hip and ridge shingle blanks 69 haveperforated edges 122. The configuration of the perforations 64 result ina perforated edge 122 which in some embodiments is somewhat ragged. Asone example, if the individual perforations 64 have a relatively longlength or if a larger quantity of perforations 64 are used, then theperforation edges 122 are somewhat smoother. Conversely, if theindividual perforations 64 have a relatively short length or if a fewernumber of perforations 64 are used, then the perforation edges 122 aresomewhat more ragged.

Referring now to FIGS. 7-9, the hip and ridge shingle blanks 69 areformed into the ridge roofing materials 24 by a series of folds. First,as shown in FIG. 7, the hip and ridge shingle blank 69 is positionedsuch that the upper surface 27 a is facing upward and the lower surface27 b is facing downward. Next, as shown in FIG. 8, the second foldregion 25 b is folded about the first perforation line 34 in directionF1 at the same time the first fold region 25 a is folded about thesecond perforation line 40 in direction F2. As shown in FIG. 9, thefolds result in a three-layered stack 53 that includes the first foldregion 25 a, the second fold region 25 b and the third region 30. Thethree-layered stack 53 has a leading edge 55. The optional sealant line66 b is shown on the first fold region 25 a and the optional sealantline 66 a is shown on the lower surface 27 b. Folding the hip and ridgesingle blanks 69 and forming the three layered stack 53 forms the ridgeroofing materials 24. As shown in FIG. 9, the resulting three layeredstack 53 has substantially aligned edges. Optionally, the resultingthree layered stack can have offset edges.

Referring again to FIG. 2, the hip and ridge roofing materials 24 areinstalled in an overlapping manner on the ridge 18 and over the shingles20. As a first installation step, a three-layered stack 53 is cut from ahip and ridge roofing material 24 and fastened to the farthest downwindpoint on the ridge 18. As shown in FIG. 2, the direction of the wind inindicated by the arrow marked W. The three-layered stack 53 can befastened by any desired fastening method, such as for example, roofingnails (not shown). Next, a hip and ridge roofing material 24 isinstalled over the three-layered stack 53 such that a portion of the hipand ridge roofing material 24 overlaps the three-layered stack 53 andthe leading edge 55 of the three-layered stack 53 is facing the winddirection W. The hip and ridge roofing material 24 is fastened to theridge 18 in any desired manner. Additional hip and ridge roofingmaterials 24 are installed in a similar fashion until the ridge 18 iscovered.

While the hip and ridge roofing material 24 illustrated in FIGS. 2 and 9illustrates a three layered stack 53, it should be appreciated that thehip and ridge roofing material 24 can be practiced with a stack formedby more than three layers. The hip and ridge roofing material 24 havinga stack of more than three layers would have a corresponding number offold regions and would be formed by folding the various fold regions toform the stack.

Referring now to FIG. 10, an apparatus 70 for manufacturing shingleblanks 26 is illustrated. The manufacturing process involves passing acontinuous sheet 72 in a machine direction (indicated by the arrow)through a series of manufacturing operations. The sheet 72 usually movesat a speed of at least about 200 feet/minute (61 meters/minute), andtypically at a speed within the range of between about 450 feet/minute(137 meters/minute) and about 800 feet/minute (244 meters/minute). Thesheet 72, however, may move at any desired speed.

In a first step of the illustrated manufacturing process, a continuoussheet of substrate or shingle mat 72 is payed out from a roll 74. Thesubstrate can be any type known for use in reinforcing asphalt-basedroofing materials, such as a non-woven web of glass fibers. The shinglemat 72 may be fed through a coater 78 where an asphalt coating isapplied to the shingle mat 72. The asphalt coating can be applied in anysuitable manner. In the illustrated embodiment, the shingle mat 72contacts a roller 73, that is in contact with a supply of hot, meltedasphalt. The roller 73 completely covers the shingle mat 72 with a tackycoating of hot, melted asphalt to define a first asphalt coated sheet80. In other embodiments, however, the asphalt coating could be sprayedon, rolled on, or applied to the shingle mat 72 by other means. In someembodiments, the asphalt material is highly filled with a ground stonefiller material, amounting to at least about 60 percent by weight of theasphalt/filler combination.

A continuous strip of the reinforcement material 36 is then payed outfrom a roll 82. The reinforcement material 36 adheres to the uppersurface 27 a of the first asphalt coated sheet 80 to define a secondasphalt coated sheet 83. In one embodiment, the reinforcement material36 is attached to the first asphalt coated sheet 80 by the adhesivemixture of the asphalt in the first asphalt coated sheet 80. Thereinforcement material 36, however, may be attached to the first asphaltcoated sheet 80 by any suitable means, such as other adhesives.

As discussed above, the reinforcement material 36 is configured to allowasphaltic material to bleed through the apertures 37 of thereinforcement material 36, thereby forming the reinforced portion 51 ofthe upper section 48 as illustrated in FIG. 5.

The resulting second asphalt coated sheet 83 is then passed beneath aseries of granule dispensers 84 for the application of granules to theupper surface 27 a of the second asphalt coated sheet 83. While theillustrated embodiment shows two granule dispensers 84, it should beunderstood that any number of granule dispensers 84 can be used. Thegranule dispensers 84 can be of any type suitable for depositinggranules onto the second asphalt coated sheet 83. A granule dispenserthat can be used is a granule valve of the type disclosed in U.S. Pat.No. 6,610,147 to Aschenbeck. The granule dispensers 84 are configured toprovide the desired blend drops of headlap and prime granules. Thegranule dispensers 84 are supplied with granules from sources ofgranules, not shown. After all the granules are deposited on the secondasphalt coated sheet 83 by the series of granule dispensers 84, thesecond asphalt covered sheet 83 becomes a granule covered sheet 85.

The granule covered sheet 85 is then turned around a slate drum 86 topress the granules into the asphalt coating and to temporarily invertthe granule covered sheet 85 so that the excess granules will fall offand will be recovered and reused. The excess granules falling from theinverted granule covered sheet can be collected in any desiredcollection device (not shown), including the non-limiting example of abackfall hopper. Turning the granule covered sheet 85 around the slatedrum forms inverted sheet 88.

A continuous strip of the release tape 39 is then payed out from a roll89 and applied to the inverted sheet 88. The release tape 39 adheres tothe lower surface 27 b of the inverted sheet 88 to define a tapedinverted sheet 90. In one embodiment, the release tape 39 is attached tothe inverted sheet 88 by the adhesive mixture of the asphalt in theinverted sheet 88. The release tape 39, however, may be attached to theinverted sheet 88 by any suitable means, such as other adhesives.

In one embodiment as shown in FIG. 10, a backdust applicator 92 ispositioned to apply a thin layer of backdust material 54 to a bottomsurface of the taped inverted sheet 90. The backdust material 54 isconfigured to adhere to the bottom surface of the taped inverted sheet90 and results in a substantially less tacky bottom surface fordownstream shingle production operations. In one embodiment, thebackdust material 54 is sand. Alternatively, the backdust material 54can be any material, such as for example natural rock dust or smallglass particles, sufficient to adhere to the bottom surface of the tapedinverted sheet 90 and result in a substantially less tacky bottomsurface. Application of the backdust material 54 to the taped invertedsheet 90 forms dusted inverted sheet 96.

Subsequent to the application of the backdust material 54 to the tapedinverted sheet 90, the dusted inverted sheet 96 is turned around a sanddrum 101 to press the backdust material 54 into the bottom surface ofthe dusted inverted sheet 96. Pressing the backdust material 56 into thedusted inverted sheet 96 forms pressed sheet 102.

Referring again to FIG. 10, the pressed sheet 102 is cooled by anysuitable cooling apparatus 104, or allowed to cool at ambienttemperature to form a cooled sheet 105.

The cooled sheet 105 is passed through optional sealant applicator 106.The sealant applicator 106 is configured to apply the optional sealantline 66 b to the first fold region 25 a of the cooled sheet 105 andapply the optional sealant line 66 a to the lower surface 27 b of thecooled sheet 105. The sealant applicator 106 can be any suitablemechanism for applying the sealant lines, 66 a and 66 b, to the cooledsheet 105. In the illustrated embodiment, a single sealant applicator106 is shown. Alternatively, any number of sealant applicators 106 canbe used. Application of the optional sealant lines, 66 a and 66 b, tothe cooled sheet 105 forms sealant lined sheet 107.

The sealant lined sheet 107 is passed through cutting roller 108 a andanvil roller 108 b. In the illustrated embodiment, the rollers, 108 aand 108 b, are configured to perform several manufacturing operations.First, the cutting roller 108 a and the anvil roller 108 b areconfigured to form the perforation lines, 34, 40, 60 and 62, each havingthe perforations 64. As discussed above, the perforations 64 can haveany desired configuration and the perforation lines, 34, 40, 60 and 62,can be positioned in any desired location. The cutting roller 108 aincludes a plurality of perforating knives 109 configured to form theperforations 64 as the cutting roller 108 a rotates and contacts thesealant lined sheet 107. The cutting roller 108 a and the anvil roller108 b are also configured to form the courtesy cuts, 68 a and 68 b.Last, the cutting roller 108 a and the anvil roller 108 b are configuredto cut the sealant lined sheet 107 to form individual shingle blanks 26.

While FIG. 10 illustrates one example of an apparatus 70 configured forforming the perforations 64, the optional courtesy cuts 68 a and 68 band cutting the individual shingle blanks 26, it should be understoodthat other suitable mechanisms or combinations of mechanisms can beused.

The shingle blanks 26 are collected and packaged such that the releasetape 39 positioned on the lower surface 27 b of the shingle blanks 26covers the optional sealant line 66 b located on the upper surface 27 aof a subsequent shingle blank 26. While the embodiment shown in FIG. 10illustrates the perforating and cutting processes as a single process,it is within the contemplation of this invention that the perforatingand cutting processes can be completed at different times and bydifferent apparatus.

While the apparatus is shown and described in terms of a continuousprocess, it should be understood that the manufacturing method can alsobe practiced in a batch process using discreet lengths of materialsinstead of continuous sheets.

The principle and mode of operation of this invention have beendescribed in certain embodiments. However, it should be noted that thisinvention may be practiced otherwise than as specifically illustratedand described without departing from its scope.

1. A shingle blank comprising: a substrate coated with an asphaltcoating and including a first fold region, a second fold region, a thirdregion, a lower edge and an upper edge, the shingle blank having alength, the first fold region extending substantially across the lengthof the shingle blank, the second fold region extending substantiallyacross the length of the shingle blank and positioned between the firstfold region and the third region; a first perforation line positionedbetween the second fold region and the third region; a secondperforation line positioned between the first fold region and the secondfold region; and a reinforcement material positioned over the firstperforation line and configured to reinforce the first perforation line,the reinforcement material including a plurality of apertures configuredto allow the asphalt coating to bleed through the reinforcementmaterial; wherein the first and second perforation lines are sufficientto facilitate folding of the first fold region and the second foldregion on top of the third region to form a three layered stackconfigured to be applied across a ridge or hip.
 2. The shingle blank ofclaim 1, wherein the portion of the shingle blank having the asphaltcoating bled through the reinforcement material forms a reinforcedregion.
 3. The shingle blank of claim 2, wherein in the first foldregion, second fold region, third region and reinforced region arecovered with prime granules.
 4. The shingle blank of claim 1, whereinthe three layered stack is positioned at one end of the shingle blank.5. The shingle blank of claim 1, wherein the first fold region and thesecond fold region have a height, wherein the height of the first foldregion and the second fold region are different.
 6. The shingle blank ofclaim 1, wherein the reinforcement material is positioned on an uppersurface of the shingle blank.
 7. The shingle blank of claim 1, whereinthe reinforcement material extends substantially across the length ofthe shingle blank.
 8. The shingle blank of claim 1, wherein thereinforcement material is formed from a polymeric material.
 9. Theshingle blank of claim 1, wherein the apertures in the reinforcementmaterial have a circular shape and a diameter in a range of from about400 microns to about 500 microns.
 10. The shingle blank of claim 1,wherein the apertures in the reinforcement material are arranged incolumns and rows.
 11. The shingle blank of claim 1, further comprising arelease tape positioned over the second perforation line and configuredto span a portion of the first fold region and the second fold region,the release tape configured to reinforce the second perforation line.12. A shingle blank comprising: a substrate coated with an asphaltcoating and including a first fold region, a second fold region, a thirdregion, a lower edge and an upper edge, the shingle blank having alength, the first fold region extending substantially across the lengthof the shingle blank, the second fold region extending substantiallyacross the length of the shingle blank and positioned between the firstfold region and the third region; a first perforation line positionedbetween the second fold region and the third region; a secondperforation line positioned between the first fold region and the secondfold region; and a release tape positioned over the second perforationline and configured to span a portion of the first fold region and thesecond fold region, the release tape configured to reinforce the secondperforation line; wherein the first and second perforation lines aresufficient to facilitate folding of the first fold region and the secondfold region on top of the third region to form a three layered stackconfigured to be applied across a ridge or hip.
 13. The shingle blank ofclaim 12, wherein the shingle blank has a lower surface, wherein arelease tape is positioned on the lower surface.
 14. A method ofmanufacturing an asphalt-based shingle blank, comprising the steps of:coating a substrate with an asphalt coating to form an asphalt coatedsheet, the asphalt coated sheet including a first fold region, a secondfold region, a third region, a lower edge and an upper edge, the shingleblank having a length, the first fold region extending substantiallyacross the length of the shingle blank, the second fold region extendingsubstantially across the length of the shingle blank and positionedbetween the first fold region and the third region; applying areinforcement material to a portion of an upper surface of the asphaltcoated sheet and over the first perforation line, the reinforcementmaterial including a plurality of apertures configured to allow theasphalt coating to bleed through the reinforcement material; applying asurface layer of granules to the upper surface of the asphalt coatedsheet; forming a first perforation line between the second fold regionand the third region; and forming a second perforation line between thefirst fold region and the second fold region.
 15. The method of claim14, wherein the shingle blank has a lower surface, wherein a releasetape is applied to a portion of the lower surface and positioned tocover the second perforation line and portions of the first and secondfold regions.
 16. The method of claim 15, wherein one additionalperforation line extends substantially across the shingle blank in adirection substantially perpendicular to the lower edge of the shingleblank.
 17. The method of claim 15, wherein hip or ridge roofingmaterials are formed by separation of the shingle blank along the atleast one additional perpendicular perforation line and folding thefirst and second perforation lines to form a three layered stack.
 18. Amethod of installing an asphalt-based roofing material, comprising thesteps of: providing an asphalt-based shingle blank having a substratecoated with an asphalt coating and including a first fold region, asecond fold region, a third region, a lower edge and an upper edge, theshingle blank having a length, the first fold region extendingsubstantially across the length of the shingle blank, the second foldregion extending substantially across the length of the shingle blankand positioned between the first fold region and the third region, afirst perforation line positioned between the second fold region and thethird region, a second perforation line positioned between the firstfold region and the second fold region, wherein at least one additionalperforation line extends across the shingle blank in a directionsubstantially perpendicular to the lower edge of the shingle blank, areinforcement material positioned over the first perforation line andconfigured to reinforce the first perforation line, the reinforcementmaterial including a plurality of apertures configured to allow theasphalt coating to bleed through the reinforcement material; separatingthe shingle blank along the at least one additional perforation line toform separated shingle blanks; folding the separated shingle blanksalong the first and second perforation lines to form a three layeredstack; and installing the hip and ridge shingles across a hip or ridge.19. The method of claim 18, wherein the shingle blank has a lowersurface, wherein a release tape is applied to a portion of the lowersurface and positioned to cover the second perforation line and portionsof the first and second fold regions.
 20. The method of claim 18,wherein the portion of the shingle blank having the asphalt coating bledthrough the apertures forms a reinforced region.